Title: Multiple-axis sculptured surface machining

Authors: John C.J. Chiou, Yuan-Shin Lee

Addresses: Unigraphics Solutions, CAM Division, Cypress, CA, USA. ' Edward Fitts Department of Industrial and Systems Engineering, North Carolina State University, NC, USA

Abstract: This paper presents swept envelope techniques to generate optimal tool paths for multiple-axis sculptured surface machining. The properties of the swept envelopes are analysed. The results help us to realise the geometric matching in tool-tip machining and understand the geometric machinability in tool-side machining. The target surfaces are classified into open-boundary sculptured surfaces and closed-boundary pocket surfaces, based on the existence of the surrounding obstacles. The objective of the open-boundary sculptured surface machining is to maximise the machining strip width of the fillet-end tools for tool-tip machining and, thus, to optimise the machining efficiency. On the other hand, the goal of the closed-boundary pocket machining is to smooth the tool axes of the ball-end tools for both tool-tip and tool-side machining and, therefore, to optimise the tool path variation. The complement of the swept envelope, which represents the in-process workpiece, is also addressed. It finally demonstrates the developed techniques and illustrates the application examples.

Keywords: computer-aided design; computer-aided manufacturing; CADCAM; five-axis machining; numerical control simulation; sculptured surfaces; pocket surfaces; CNC machining; NC simulation; swept envelopes; tool path generation; machining efficiency; tool path variation.

DOI: 10.1504/IJMR.2006.011354

International Journal of Manufacturing Research, 2006 Vol.1 No.2, pp.213 - 247

Published online: 22 Nov 2006 *

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